CN110991108A - Method for designing structure of mechanical arm joint torque sensor - Google Patents
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Abstract
The invention discloses a structural design method of a mechanical arm joint torque sensor, and aims to provide an efficient design tool for developing a novel mechanical arm joint torque sensor with high sensitivity and high rigidity. The method comprises the steps of firstly, obtaining an initial configuration of a sensor elastomer from a design requirement; secondly, selecting design variables by taking the initial configuration as a reference, constructing a standard structure optimization design model by taking the stress-strain ratio of the elastic body of the sensor as a design target, and solving the model to output an optimal design scheme. Compared with the conventional method, the method does not need a designer to provide an initial configuration, so that the dependence on engineering experience and theoretical knowledge is greatly reduced; all steps in the design process do not need complicated and complex programming solving processes, and the method is easy to understand and implement and has good engineering practicability.
Description
Technical Field
The invention relates to the technical field of torque sensors, in particular to a structural design method of a mechanical arm joint torque sensor.
Background
Robotic arms have been widely used in industrial fields such as vehicles, electronics, shipbuilding, etc. In order to effectively control the mechanical arm, a plurality of sensors are arranged to monitor the state of each key position in real time, and a torque sensor is the most widely used sensor. The torque sensor is usually designed at the position of the moving joint, and effective compensation of motion control errors can be realized based on signals fed back by the torque sensor. Elastomers are the structural core of joint torque sensors and numerous configurations have been developed to date. Among them, more typically include: hollow circular ring type, hub type, cross type, spoke type, etc. The design goals of the joint torque sensor configuration described above are mainly focused on two aspects: sensitivity and torsional rigidity. The greater sensitivity means that the greater the response stress on the elastomer under the same preload, the stronger voltage signal can be output under the piezoresistive effect. The larger the torsional rigidity is, the smaller the angular strain of the elastic body is, and the smaller the additional deformation error introduced to the joint position of the mechanical arm is. Typically, such errors are difficult to compensate. Thus, designers desire both high sensitivity and high torsional stiffness, i.e., greater stress and less angular strain. However, studies have shown that there is a restrictive relationship between the two; in other words, raising the response stress of the sensor elastomer tends to increase its angular strain. Naturally, stress-strain ratio is used as a key performance indicator to evaluate the design effectiveness of such sensors.
As previously mentioned, a number of torque sensor design configurations have been developed. However, as the industrial demands for cost performance of sensors increase, designers need to continually improve sensor performance by proposing new configurations. The basic idea of the conventional design method is to first provide a new configuration and then further optimize the design based on the configuration. The proposal of a new configuration is challenging for designers, and the process not only depends on rich engineering experience, but also needs to have a deep theoretical foundation. As such, the design and development of new joint torque sensors face serious obstacles. The design method of the joint torque sensor structure is independent of engineering experience, easy to understand and implement, and has very important engineering significance for promoting the rapid development of the mechanical arm with high cost performance.
Disclosure of Invention
The invention overcomes the defects of the prior art, and provides a structural design method of a mechanical arm joint torque sensor, which does not need to provide an initial configuration for a sensor elastomer, thereby greatly reducing the dependence on engineering experience and theoretical knowledge, and providing an efficient design tool for developing a novel mechanical arm joint torque sensor with sensitivity and torsional rigidity.
In order to achieve the purpose, the invention adopts the following technical scheme: a mechanical arm joint torque sensor structure design method comprises the following steps:
(1) selecting an elastomer part of a joint torque sensor to be optimized as a design area, and defining a design target, wherein the design target is set as: S/ERUnder preload, where S represents the maximum equivalent stress of the sensitive zone of the elastomer, ERRepresenting a maximum angular strain of the elastomeric support region;
(2) establishing a finite element analysis model A, and simulating the stress-strain response of the elastomer under the angular displacement load;
(3) establishing a topological optimization model based on the finite element analysis model A and solving to obtain a topological configuration;
(4) converting the topological configuration into an initial design, selecting design variables which need to be kept unchanged, and forming a design vector X (X) by the selected design variables1,X2,...,XN) (ii) a The value range is as follows: xi∈[Xi L,Xi R],i＝1,2,...,N；
(5) Constructing an equivalent stress function and an angular strain function based on the design variables;
(6) establishing a structure optimization model, solving and outputting an optimal design scheme;
the structural optimization model is as follows:
optimal design: x*＝(X1 *,X2 *,...,XN *)。
Further, in step (1): on the elastic body, 8 first moving shaft fixing holes are arranged in the outer circumferential area and used for connecting the moving shaft; the central area is provided with 4 first dead axle fixing holes for connecting the dead axle, and 4 first sensitive areas for respectively placing 4 piezoresistors to form a Wheatstone bridge circuit so as to complete the monitoring of the input torque.
Further, in step (2), the process of establishing the finite element analysis model a is as follows:
(2.1) building a shell-feature-based structural model for the elastomer;
(2.2) dividing a sensitive area according to design requirements;
(2.3) applying a fixed support boundary condition to the dead axle fixing hole;
(2.4) applying an angular displacement boundary condition to the moving shaft fixing hole, and setting an angular displacement RZ；
And (2.5) carrying out general static analysis on the existing finite element analysis software platform to obtain the equivalent stress distribution and the angular strain distribution of the elastomer.
Further, in the step (3), the process of establishing a topology optimization model and solving to obtain a topology configuration is as follows:
(3.1) selecting a region to be designed in the finite element analysis model A;
(3.2) freezing the region where the boundary condition is set;
(3.3) establishing a design response function of the total strain energy E of the sensitive area based on the finite element analysis model A;
(3.4) establishing a design response function of the volume V based on the region to be designed;
(3.5) maximizing E as a design target, and V is less than or equal to V0For constraint, the following topology optimization model is established:
and (3.6) solving on the existing finite element analysis software platform, and outputting the topological configuration of the region to be designed.
Further, in step (3.5), V0∈[15％，40％]。
Further, V0＝20％。
Further, in step 4, the topological configuration is standardized according to the process requirement of single-tool single-station milling, so as to obtain an initial design.
Further, the initial design comprises a first datum line, a second datum line and a third datum line, and the first datum line is offset by X1Obtaining a first contour line, and shifting X with the second reference line2Obtaining a second contour line, shifting by a third datum line3Obtaining a third contour; this results in a new design, in which 3 offsets X1，X2，X3For selected design variables, a design vector X ═ X (X) may be composed1，X2，X3) (ii) a The value range is as follows: xi∈[Xi L,Xi R]。
Further, Xi L＝0mm,Xi L＝3mm,i＝1,2,3。
Further, in step (5), the process of constructing the equivalent stress function and the angular strain function is as follows:
(5.1) establishing a shell-feature-based finite element analysis model B for the design scheme;
(5.2) dividing a sensitive area and a supporting area;
(5.3) applying a clamped boundary condition to the dead axle fixing hole;
(5.4) applying torque to the fixed hole of the moving shaftLoad MZ；
(5.5) carrying out general static analysis based on an ABAQUS finite element analysis software platform to obtain the maximum equivalent stress S (X) of a sensitive area and the maximum angular strain E of a supporting area under a certain design scheme XR(X)；
(5.6) by the response surface technique, for S (X) and ER(X) establishing an explicit approximation function.
Compared with the prior art, the invention has the advantages that:
firstly, the method can directly obtain the initial configuration of the sensor elastomer from the design requirement, thereby greatly reducing the dependence of designers on engineering experience and theoretical basis. Secondly, the method further optimizes the initial configuration by constructing a standard optimization model, and can realize the optimal structural design of the joint torque sensor with sensitivity and torsional rigidity. In conclusion, the method is easy to understand and implement and has good engineering practicability.
Drawings
FIG. 1 is a schematic flow diagram of the process of the present invention.
FIG. 2 is a schematic diagram of a torque sensor in an embodiment of the present invention.
FIG. 3 is a finite element analysis model under angular displacement loading in an example embodiment of the present invention.
Fig. 4 is a simulated equivalent stress distribution and angular strain distribution in a specific application example of the present invention.
FIG. 5 shows a topology and a preliminary design of an embodiment of the present invention.
FIG. 6 shows design variables in an example embodiment of the present invention.
FIG. 7 is a finite element analysis model under torque loading in an example embodiment of the present invention.
FIG. 8 shows the best design obtained in the specific application example of the present invention and two common designs for comparison.
Reference numerals: 20. an elastomer; 21. a first moving shaft fixing hole; 22. a first stationary shaft fixing hole; 23. a first sensitive area; 24. a first support region; 30. a first finite element analysis model; 32. a first clamped boundary condition; 321. a second moving shaft fixing hole; 322. a second stationary shaft fixing hole; 323. a second sensitive area; 33. a first control point; 34. a first coupling constraint; 35. an angular displacement boundary condition; 36. a first region; 37. a second region; 38. a third region; 41. equivalent stress distribution; 42. angular stress distribution; 51. a topological configuration; 52. initial design; 60. a first design solution; 601. a first reference line; 602. a second reference line; 603. a third reference line; 611. a first contour line; 612. a second contour line; 613. a third contour; 70. a second finite element analysis model; 72. a second clamped boundary condition; 721. a third moving shaft fixing hole; 722. a third stationary shaft fixing hole; 723. a third sensitive area; 73. a second control point; 74. a second coupling constraint; 75. a torque load; 76. a second support region; 80. a second design scheme; 801. a fourth region; 802. a seventh region; 81. designing a hub shape; 811. a fifth region; 812. an eighth region; 82. designing a spoke type; 821. a sixth region; 822. a ninth area.
Detailed Description
The invention will now be further described with reference to the following examples, which are not to be construed as limiting the invention in any way, and any limited number of modifications which can be made within the scope of the claims of the invention are still within the scope of the claims of the invention.
As shown in fig. 1-8, the invention provides a structural design method of a torque sensor of a mechanical arm joint, which comprises the following processing steps:
step S1: and selecting an elastomer part of the joint torque sensor to be optimized as a design area, and defining a design target. As shown in fig. 2, the elastic body 20 of the joint torque sensor to be optimized in the present embodiment is designed and manufactured based on aluminum alloy (AL7075), and its elastic modulus is set to 71.7GPa and poisson's ratio is 0.33. On the elastic body 20, 8 first moving shaft fixing holes 21 are designed in the outer circumferential area and used for connecting a moving shaft; 4 first dead axle fixing holes 22 are designed in the central area and are used for connecting the dead axles; 4 first sensitive zones 23 are provided for placing 4 piezoresistors respectively to form a wheatstone bridge circuit. The torque induced by the relative rotation of the moving shaft and the static shaft causes elasticityA response stress occurs on the body 20; under the action of piezoresistive effect, the piezoresistor on the sensitive area 23 generates resistance value change; and outputting a corresponding voltage signal through a Wheatstone bridge circuit so as to complete the monitoring of the input torque. On the elastic body 20, a region excluding the first moving shaft fixing hole 21, the first stationary shaft fixing hole 22, and the first sensitive region 23 may be referred to as a first support region 24. The maximum equivalent stress of the first sensitive zone 23 is: s, the maximum angular strain of the first support region 24 is: eR(ii) a The design target is set as follows: S/ER。
Step S2: and establishing a finite element analysis model to simulate the stress-strain response of the elastic body 20 under the angular displacement load. As shown in fig. 3, a shell-feature based first finite element analysis model 30 is established for the elastomer 20; dividing 4 second sensitive regions 323 according to design requirements, wherein the second sensitive regions 323 correspond to the first sensitive regions 23 shown in FIG. 2; applying a first clamped boundary condition 32 to the second dead axle securing hole 322; applying a first coupling constraint 34 based on a first control point 33 to the second moving axis fixing hole 321, and applying an angular displacement boundary condition 35 based on Z-direction rotation on the first control point 33, wherein the angular displacement is RZ0.001 rad; the second moving shaft fixing hole 321 and the second stationary shaft fixing hole 322 correspond to the first moving shaft fixing hole 21 and the first stationary shaft fixing hole 22 shown in fig. 2, respectively; a general static analysis was performed on the ABAQUS finite element analysis software platform to obtain an equivalent stress distribution 41 and an angular strain distribution 42 as shown in fig. 4.
Step S3: based on the finite element analysis model 30, a topological optimization model is established and solved to obtain a topological configuration. As shown in fig. 3, a first region 36 is selected as a region to be designed in the finite element analysis model 30; freezing a second region 37 including a second moving shaft fixing hole 321 and a third region 38 including a fixed shaft fixing hole 322; establishing a design response function of the total strain energy E of the second sensitive area 323 based on the finite element analysis model 30; establishing a design response function of the volume V based on the first region 36 to be designed; taking the maximum E as a design target and V is less than or equal to V0And (3) establishing the following topological optimization model by taking 20% as constraint:
the topological configuration 51 of the first region 36, which is output as a design region, is solved on the ABAQUS finite element analysis software platform, as shown in fig. 5.
Step S4: the resulting topological configuration 51 is converted to an initial design 52 and design variables are selected. According to the technological requirements of single-tool single-station milling, the topological structure 51 is subjected to standardization processing to obtain an initial design 52 shown in FIG. 5; design variables are selected while maintaining the original design 52 configuration. As shown in FIG. 6, a first datum line 601, a second datum line 602, and a third datum line 603 are obtained based on the initial design 52, offset by X from the first datum line 6011The first contour line 611 is obtained by offsetting X with the second datum line 6022A second contour line 612 is obtained, shifted by X from the third datum line 6033A third contour line 613 is obtained; thereby resulting in a new design 60. Of which 3 offsets (X)1，X2，X3) For selected design variables, a design vector X ═ X (X) may be composed1，X2，X3) (ii) a The value range is as follows: xi∈[Xi L,Xi R],Xi L＝0mm,Xi L＝3mm,i＝1,2,3。
Step S5: based on the design variables, equivalent stress functions and angular strain functions are constructed. As shown in FIG. 7, a second finite element analysis model 70 based on shell-features is established for the first design scenario 60; dividing 4 third sensitive regions 723, wherein the third sensitive regions 723 correspond to the second sensitive regions 323 shown in fig. 3; applying a second clamped boundary condition 72 to the third dead axle securing hole 722; the second coupling constraint 74 based on the second control point 73 is applied to the third moving shaft fixing hole 721, and the torque load 75 based on the Z direction is applied to the second control point 73, the torque being set to MZ10 n.m; a second supporting region 76 is divided so as not to include the third movable shaft fixing hole 721, the third fixed shaft fixing hole 722 and the third sensitive region 723; the third moving shaft fixing hole 721 and the third stationary shaft fixing hole 722 correspond to the second moving shaft fixing hole 321 and the second stationary shaft fixing hole 322 shown in fig. 3, respectively. In ABAQUS there areThe maximum equivalent stress S (X) of the third sensitive area 723 and the maximum angular strain E of the second support area 76 under a certain design scheme X can be obtained by performing general static analysis on a finite element analysis software platformR(X). By randomly sampling 50 times in the range of design variable values, S (X) and ER(X) establishing a second order response surface function, which can be written as:
S(X)＝8.585-1.852X1-0.881X2-0.486X3+0.721X1 2+0.002X2 2-0.057X3 2-0.128X1.X2-0.220X1.X3+0.141X2.X3
ER(X))＝4.062-1.750X1-0.611X2-1.090X3+1.138X1 2+0.508X2 2+0.647X3 2-0.398X1.X2-0.097X1.X3+0.151X2.X3
step S6: and establishing a structure optimization model, solving and outputting an optimal design scheme. With S (X)/ER(X) for design purposes, the structure optimization model is established as follows:
solving the optimization model by adopting a classical quadratic sequence programming method to obtain an optimal design: x*＝(0.70mm,0.46mm,0.67mm)，S(X)＝6.81MPa，ER(X)＝2.66e-4。
To demonstrate the beneficial effects of the proposed method, the optimal design was compared to the two common designs for performance. As described in the background, the greater the equivalent stress of the sensitive region, the higher the sensitivity of the torque sensor; the smaller the angular strain of the elastic body is, the better the rigidity of the torque sensor is and the better the linearity is; therefore, stress-strain ratios are employed in the present embodiment to gauge the performance of the torque sensor design. As shown in fig. 8, the hub-type design 81 and the spoke-type design 82 are two designs common to joint torque sensor elastomers, and the second design 80 is the optimal design. The fourth area 801, the fifth area 811 and the sixth area 821 are sensitive areas of the second design 80, the hub design 81 and the spoke design 82 respectively, and the seventh area 802, the eighth area 812 and the ninth area 822 are support areas of the second design 80, the hub design 81 and the spoke design 82 respectively. For the second design 80, the hub-type design 81 and the spoke-type design 82, a finite element analysis similar to step S5 was performed to extract the maximum equivalent stresses of the fourth area 801, the fifth area 811 and the sixth area 821 as sensitive areas and the maximum angular strains of the seventh area 802, the eighth area 812 and the ninth area 822 as support areas, as listed in table 1. From the results, it can be seen that the resulting second design 80 has the greatest stress-strain ratio (2.56), 2.5 times that of the hub design 81, 3.4 times that of the spoke design 82; thus, the proposed method results in the second design 80 having the best performance of the three designs, and the performance advantage over the hub and spoke designs 81 and 82 is significant. On the other hand, from the whole design process of the embodiment, a designer can obtain the initial configuration of the elastic body of the torque sensor without depending on engineering experience, and the method has better engineering practicability compared with the conventional method.
TABLE 1
Claims (10)
1. A mechanical arm joint torque sensor structure design method is characterized by comprising the following processing steps:
(1) selecting an elastomer part of a joint torque sensor to be optimized as a design area, and defining a design target, wherein the design target is set as: S/ERWherein S represents the maximum equivalent stress of the sensitive zone of the elastomer, ERRepresenting a maximum angular strain of the elastomeric support region;
(2) establishing a finite element analysis model A, and simulating the stress-strain response of the elastomer under the angular displacement load;
(3) establishing a topological optimization model based on the finite element analysis model A and solving to obtain a topological configuration;
(4) converting the topological configuration into an initial design, selecting design variables which need to keep the initial design configuration unchanged, and forming a design vector X (X) by the selected design variables1,X2,...,XN) (ii) a The value range is as follows: xi∈[Xi L,Xi R],i＝1,2,...,N；
(5) Constructing an equivalent stress function and an angular strain function based on the design variables;
(6) establishing a structure optimization model, solving and outputting an optimal design scheme;
the structural optimization model is as follows:
2. the structural design method of the mechanical arm joint torque sensor according to claim 1, wherein in the step (1): on the elastic body, 8 first moving shaft fixing holes are arranged in the outer circumferential area and used for connecting the moving shaft; the central area is provided with 4 first dead axle fixing holes for connecting the dead axle, and 4 first sensitive areas for respectively placing 4 piezoresistors to form a Wheatstone bridge circuit so as to complete the monitoring of the input torque.
3. The structural design method of the torque sensor of the joint of the mechanical arm as claimed in claim 1, wherein in the step (2), the process of establishing the finite element analysis model A is as follows:
(2.1) building a shell-feature based structural model for the elastomer;
(2.2) dividing a sensitive area according to design requirements;
(2.3) applying a fixed support boundary condition to the dead axle fixing hole;
(2.4) applying an angular displacement boundary condition to the moving shaft fixing hole, and setting an angular displacement RZ；
And (2.5) carrying out general static analysis on the existing finite element analysis software platform to obtain the equivalent stress distribution and the angular strain distribution of the elastomer.
4. The structural design method of the torque sensor of the mechanical arm joint according to claim 1, wherein in the step (3), the process of establishing a topology optimization model and solving to obtain a topology configuration comprises the following steps:
(3.1) selecting a region to be designed in the finite element analysis model A;
(3.2) freezing the region where the boundary condition is set;
(3.3) establishing a design response function of the total strain energy E of the sensitive area based on a finite element analysis model A;
(3.4) establishing a design response function of the volume V based on the region to be designed;
(3.5) maximizing E as a design target, and V is less than or equal to V0For constraint, the following topology optimization model is established:
and (3.6) solving on the existing finite element analysis software platform, and outputting the topological configuration of the region to be designed.
5. The structural design method of the torque sensor of the joint of the mechanical arm as claimed in claim 4, wherein in the step (3.5), V is0∈[15％，40％]。
6. The structural design method of the torque sensor of the joint of the mechanical arm as claimed in claim 5, wherein V is0＝20％。
7. The structural design method of the torque sensor of the joint of the mechanical arm as claimed in claim 1, wherein in step 4, the topological configuration is standardized according to the process requirement of single-tool single-station milling to obtain an initial design.
8. The structural design method of a torque sensor of a joint of a mechanical arm as claimed in claim 7, wherein the initial design includes a first datum line, a second datum line and a third datum line, and the first datum line is offset by X1Obtaining a first contour line, and shifting X with the second reference line2Obtaining a second contour line, shifting by a third datum line3Obtaining a third contour; this results in a new design, in which 3 offsets X1，X2，X3For selected design variables, a design vector X ═ X (X) may be composed1，X2，X3) (ii) a The value range is as follows: xi∈[Xi L,Xi R]。
9. The structural design method of the torque sensor of the joint of the mechanical arm according to claim 8, wherein X isi L＝0mm,Xi L＝3mm,i＝1,2,3。
10. The structural design method of the torque sensor of the mechanical arm joint according to any one of claims 1 to 9, wherein in the step (5), the equivalent stress function and the angular strain function are constructed by the following processes:
(5.1) establishing a shell-feature-based finite element analysis model B for the design scheme;
(5.2) dividing a sensitive area and a supporting area;
(5.3) applying a clamped boundary condition to the dead axle fixing hole;
(5.4) applying a torque load M to the moving shaft fixing holeZ；
(5.5) carrying out general static analysis based on a finite element analysis software platform to obtain the maximum equivalent stress S (X) of the sensitive area and the maximum angular strain E of the supporting area under a certain design scheme XR(X)；
(5.6) by the response surface technique, for S (X) and ER(X) establishing an explicit approximation function.
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Application publication date: 20200410 Assignee: Hunan Hongyuyun Technology Co.,Ltd. Assignor: Hunan City University Contract record no.: X2023980052592 Denomination of invention: A Structural Design Method for Robot Arm Joint Torque Sensor Granted publication date: 20230425 License type: Common License Record date: 20231215 |